Plant Management
By
Dr. Ravi K. Peetala
Assistant Professor
Department of Mechanical Engineering
VNIT Nagpur
Lecture -1
Plant Management
1. Plant Location
2. Plant layout
3. Type of maintenance (Break down,
predictive and preventive maintenance)
4. Stores of management
5. Production planning and control
Factors in Plant (facility) location
1. Process input
2. Process output
3. Process characteristics
4. Personal preference
5. Govt. policy
6. Local conditions
7. Cost factors
8. Competition
9. Intangible factors
Considerations of Plant location
Near to raw material source
Near to Market
Good transportation facility
Availability of labour
Availability of power and water
Cheap availability of land
Availability of sub-contractor, industrial climate
Taxes and govt. regulations
Site for waste disposal and environmental regulations.
What is Layout Planning?
Layout planning is determining the best
physical arrangement of resources within a
facility
Objectives of Facility Layout
A facility layout problem may have many objectives. In the
context of manufacturing plants, minimizing material handling
costs is the most common one.
Other objectives include efficient utilization of
space
labor
Eliminate
bottlenecks
waste or unnecessary movement
Objectives of Facility Layout
Facilitate
organization structure
communication and interaction between workers
manufacturing process
visual control
Minimize
manufacturing cycle time
investment
Provide
convenience, safety and comfort of the employees
flexibility to adapt to changing conditions
Types of Layouts
Process layouts: Group similar resources together
Product layouts: Designed to produce a specific product,
or a small number of products efficiently
Group or Cellular layouts: A cell contains a group of machines
dedicated for a group of similar parts.
Suitable for producing a wide variety parts in moderate
volume
Fixed-Position layouts: Product is too large to move
Examples: building construction, shipyard
Resources must be brought to where they are needed
Process and Product Layouts
Product Layouts
Used in assembly lines and continuous manufacturing
(repetitive processes).
In manufacturing, product layouts are used to produce one
product, or a small group of products, efficiently
Used in a flow shop for a high volume, standard products.
More automation than in process layouts
Material handling costs per unit are lower than in process
layouts
Scheduling production is simpler than in process layouts
Process Layouts
Used in project and batch manufacturing (intermittent
processes).
Able to make or sell a variety of products
Used in a job shop for a low volume, customized
products
Less automation than in product layouts
Material handling costs per unit are higher than in
product layouts
Scheduling production is more complex than in product
layouts.
Group or Cellular Layouts
• Every cell contains a group of machines which are
dedicated to the production of a family of parts.
• One of the problems is to identify a family parts that
require the same group of machines.
• These layouts are also called as group technology
layouts.
• Suitable for producing a wide variety parts in moderate
volume
Cellular Layouts Example
Assembly
4 6 7 9
5 8
2 10 12
1 3 11
A B C Raw materials
Cellular Layouts Example
Assembly
8 10 9 12
11
4 Cell1 6 Cell 3
Cell 2
7
2 1 3 5
Raw materials A C B
Each of A, B, C now visits only one area, minimizing jumping.
Advantages of Cellular Layouts
• Reduced material handling and transit time
• Reduced setup time
• Reduced work-in-process inventory
• Better use of human resources
• Better scheduling, easier to control and automate
Disadvantages of Cellular Layouts
• Sometimes cells may not be formed because of insufficient
part families.
• Some cells may have a high volume of production and
others very low. This results in poorly balanced cells.
Disadvantages of Cellular Layouts
• When volume of production changes, number of workers are
adjusted and workers are reassigned to various cells.
To manage with this type of reassignments, workers must be
multi-skilled and cross-trained.
• Sometimes, machines are duplicated in different cells. This
increases capital investment.
Production volume and product variety
determines type of layout
production product group layout process layout
production layout
volume
volume
Fixed
Position
Layouts
product variety
Lecture -2
Plant Management
By
Dr. Ravi K. Peetala
Assistant Professor
Department of Mechanical Engineering
VNIT Nagpur
Plant management
Men,
Machines Desirable
Material
Money Production system Goods/services
Energy
Information Undesirable output
Pollution
Noise
scrap
Purpose of layout, to facilitate production process and
try to improve the production system
Types of Layouts
Process/Job shop layout
Product/flow shop layout
Group or Cellular layout
Fixed-Position layout
Process/Job shop Layout
Facilities capable of producing many different jobs in small
batches.
Similar items are grouped together.
Advantages of process layout :
Better utilization of machines, hence few machines
needed.
Comparatively low investment in machine required.
Greater job satisfaction for operator.
Specialized supervision is possible.
Limitations of process layout :
Longer flow lines usually results, material handling is
more expensive.
Total production time usually longer.
Large process inventories.
Group/Cellular Layout
Each station on the manufacturing floor is capable of
performing all the steps needed to make a product.
Every cell contains a group of machines which are dedicated
to the production of a family of parts.
These layouts are also called as group technology layouts.
Suitable for producing a wide variety parts in moderate
volume
Cellular Layouts Example
Assembly
8 10 9 12
11
4 Cell1 6 Cell 3
Cell 2
7
2 1 3 5
Raw materials A C B
Each of A, B, C now visits only one area, minimizing jumping.
Advantages of Cellular Layouts
• Reduced material handling and transit time
• Reduced setup time
• Reduced work-in-process inventory
• Better use of human resources
• Better scheduling, easier to control and automate
Disadvantages of Cellular Layouts
• Sometimes cells may not be formed because of insufficient
part families.
• Some cells may have a high volume of production and
others very low. This results in poorly balanced cells.
Disadvantages of Cellular Layouts
• When volume of production changes, number of workers are
adjusted and workers are reassigned to various cells.
To manage with this type of reassignments, workers must be
multi-skilled and cross-trained.
• Sometimes, machines are duplicated in different cells. This
increases capital investment.
Product/ flow shop layout:
The same set of operations performed in sequence
repetitively .
Underline ideas of mass manufacture
Logical breakdown of work (smaller tasks &
Division of labour).
Division of work into work stations.
-- Adam smith
---Henry Ford (first assembly line)
Interchangeable and replaceable parts
-- E. whitney.
Advantages Product Layouts
Smooth flow of material from one work station to next.
Since work fed from one station to next small in process
inventory.
Total production time is less.
Reduced material handling.
Little skill required by operations. Hence training simple, short
and inexpensive.
Simple production planning and control.
Less space occupied by work in transit for temporary storage.
Disadvantages of Product Layouts
A breakdown of machine may lead to a complete stoppage of
following machines, hence maintenance is a challenging job.
Inflexible with regard to changes product design.
Line balancing is the major a problem in design.
Design of an assembly line
The Objective :
Minimize the total ideal time (or) the no. of work stations
for a given assembly line speed.
Division of work into parts
The precedence diagram
Grouping of the tasks into work stations
The feasible range of cycle times.
Line balancing methods
-- Helgeson &birnie (RPW-Rank position weight )
-- Kilbridge & wester (No. of predecessors)
Choice of the best design.
Ranked positional weights
The positional weight on a work element is its own
processing time plus the processing times of all the following
work elements.
At each work station a list of eligible jobs is prepared for
placement.
In RPW, the work element with the highest positional weight
is selected and assigned to the current work station.
Lecture -3
Production planning and control
Production planning is a managerial function which is mainly
concerned with the following important issues :
What production facilities are required ?
How these production facilities should be laid out in the
space available for production ?
How they should be used to produce the desired products at
the desired rate of production?
Production planning
Production planning is dynamic in nature and always remains in
fluid state, as plans may have to be changed according to the
changes in circumstances.
Production planning is usually done at the following three
horizon levels:
Long Term (Capacity Planning)
Medium term (Aggregate Planning)
Short Term (Operational Planning)
Long Term (Capacity Planning):
Up to 5 years ahead or more
Strategic/business issues
Medium term (Aggregate Planning):
Up to 2 years ahead
How can demand be met from existing facilities and
resource inputs ?
Short term (operational planning) :
Monitoring and correction of day to day activities versus
plan.
Requirements of production Planning
1.It should be based on accurate data.
2.It must be flexible
3.It must satisfy a set of pre-defined objectives (Economy,
quality etc.)
4.It must be simple and straight forward
5.It should have a reporting system, so that right information
reaches at right place and at right time.
Production Control
Production control is a mechanism to monitor the execution of the
plans. it has several important functions;
Making sure that production operations are started at planned
places and planned times.
Observing progress of the operations and recording it properly.
Analyzing the recorded data with the plans and measuring the
deviations.
Open Loop control system
Closed Loop control system
Production Control
Control involves the monitoring and correction of operations to
ensure that plans and objectives are being met.
Many different forms of production control :
1. Quality control
2. Stock control
4. Cost control (budgeting)
5. People and labour productivity
Functions of production planning and
control
Product Planning :
Product engineering, product design and development, functional
and technological considerations, quality considerations.
Forecast Planning :
Quantity forecast, demand pattern forecast.
Process Planning :
Technology selection, process selection, machine selection, tool
selection, process parameter selection, operation sequencing etc..
Functions of production planning and
control
Equipment Planning :
Type of equipments, number of equipments, machine capability
analysis, maintenance planning.
Materials Planning :
Material specifications, material volumes, economic lot sizing,
inventory planning, store planning.
Loading, Scheduling and Sequencing:
Machine loadings, operations scheduling, job sequencing etc.
Plant maintenance
The objective of plant maintenance is to achieve
minimum breakdown and to keep the plant in good
working condition at the lowest possible cost.
Importance of plant maintenance
1. Equipment breakdown leads to an unavoidable loss of
production.
2. Plant maintenance plays a prominent role in production
management because plant break down creates
problem such as
-- Loss in production.
-- Rescheduling of production.
-- Temporary work shortages for workers.
Types of Plant maintenance
1. Corrective or breakdown maintenance
2. Preventive maintenance
3. Predictive maintenance
4. Scheduled maintenance
Corrective or Breakdown maintenance
Corrective or Breakdown maintenance implies that repairs are
made after the equipment is out of order and it cannot perform
its normal functions any longer.
Typical causes of equipment breakdown:
1. Failure to replace damaged out parts
2. Lack of lubrication
3. Neglecting cooling system
4. External factors
Preventive maintenance
Preventive maintenance tries to minimize the problems of
breakdown maintenance.
Objectives:
1. To minimize the possibility of unexpected production interruption.
2. To make plant equipment and machinery always available and ready for
use.
3. To achieve maximum production at minimum repair cost.
Predictive maintenance
It is comparatively a newer maintenance technique.
It makes use of human senses or other sensitive instruments
such as vibration analyzer, pressure, temperature and
resistance strain gauges, etc.. To predict troubles before the
equipment fails.
Scheduled maintenance
Scheduled maintenance is a stich-in-time procedure aimed
at avoiding breakdowns.
Scheduled maintenance practice incorporates , inspection,
lubrication, repair etc..
